Asymmetric transfer molding method and an asymmetric encapsulation made therefrom

ABSTRACT

A method of encapsulating an article having first and second surfaces, includes positioning a first molding section in a sealing relationship with the first surface of the article and positioning a second molding section adjacent the second surface of the article. The first molding section is filled first thereby forcing the second surface of the article into a sealing engagement with the second molding section. The second molding section is then filled.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The invention relates to a method of encapsulating an article and, more specifically, to transfer molding an asymmetric encapsulation for an electronic device, and an asymmetric encapsulated electronic device.

[0003] 2. Description of the Background

[0004] It is well known that electronic devices are sensitive and thus require protection from physical and environmental conditions which may degrade or completely ruin them. Therefore, it is well known in the art to protect electronic devices from these conditions by sealing them with a protective encapsulation material. This “packaging” of the electronic devices protects them from the conditions which may degrade them and allows the devices to be transported and handled, and thus allows them to be easily configured with other components. Several encapsulation methods are known in the art such as under-fill encapsulation (for flip chip applications) and glob topping.

[0005] One prior-art method for encapsulating devices is the “transfer-molding” method. Transfer molding is a process through which an encapsulating material, such as a thermosetting material, is caused to flow into a cavity formed by components of a mold. The thermosetting material enters into the cavity and flows over the electronic device[s] that is[are] located within the cavity and is then “cured” so that the resin hardens into a non-flowable state. Traditionally it has been important to control the flow of the material into the cavity for a number of reasons, including: to provide void-free fill over the electrical device, to control the flow of the material so as to not contaminate unwanted areas with the encapsulating material, and to control the flow of the material so as to not cause any wire displacement or other damage to the assembly.

[0006] Also, it is well known in the art to use mechanical clamping mechanisms as sealing devices in conjunction with the molding cavity to attempt to contain the thermosetting resin within the cavity prior to curing. However, because mechanical clamps must be applied in a symmetrical fashion, i.e. equal and opposite clamping forces, the configuration of the molds is limited to symmetrical designs.

[0007] Therefore there is a need for an improved encapsulation method for transfer molding electronic devices which provides a leak proof sealing mechanism for asymmetric designs while using current equipment and known materials and techniques.

SUMMARY OF THE INVENTION

[0008] In accordance with one aspect of the present invention, a method of encapsulating an article having first and second surfaces includes the following steps: positioning a first molding section in a sealing relationship with the first surface of the article; positioning a second molding section adjacent the second surface of the article; filling the first molding section thereby forcing the second surface of the article into a sealing engagement with the second molding section; and filling the second molding section. Additionally, the step of filling the first and second molding sections may include the step of filling the first and second molding sections with an encapsulating material chosen from a class consisting of epoxies (including thermo-set resins), silicones, sycar, polyimides, and polyurethanes. Also, depending on the type of encapsulating material that is chosen, an optional step of curing the encapsulating material may be required.

[0009] Another aspect of the present invention is to provide a method which includes the following steps: mounting an electrical device to a first surface of a flexible substrate such that leads from the electrical device extend to a second surface of the flexible substrate; connecting the leads to traces formed in the second surface of the flexible substrate; positioning a portion of the flexible substrate carrying the electrical device within a molding cavity defined by first and second molding sections, the substrate forming a seal with the first molding section; forming a seal between the substrate and the second molding section by filling the first molding section; and filling the second molding section.

[0010] Another aspect of the present invention is to provide a method of transfer molding, including the steps of: positioning a first portion of encapsulated material on a first surface by transfer molding; and positioning a second portion of encapsulated material, of smaller surface area than the first portion, on a second surface by transfer molding.

[0011] Another aspect of the present invention is to provide a mold, which includes: a first molding section and a second molding section. The first and second molding sections form a cavity for receiving an article to be encapsulated. The surface area of a first side of an article exposed to the cavity is greater than the surface area of a second side of the article exposed to the cavity. At least one gate for injecting encapsulating material into the cavity is provided.

[0012] Another aspect of the present invention is to provide a non-symmetrical, transfer molded, encapsulated article.

[0013] The present invention provides several advantages over prior art techniques. Yields are increased in comparison to parts which are glob topped. The method of the present invention may be carried out using existing processes and materials having well known and understood properties. Additionally, existing molding equipment may be used. Assembly throughput is increased. Those advantages and benefits, and others, will be apparent to those of ordinary skill in the art from the Description of a Preferred Embodiment, herein below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] For the present invention to be readily understood and practiced, the invention will now be described, for purposes of illustration and not limitation, in conjunction with the following figures wherein:

[0015]FIG. 1 illustrates a substrate which may be used in conjunction with the method of the present invention;

[0016]FIG. 2 illustrates a portion of the substrate of FIG. 1 carrying an electrical device to be encapsulated;

[0017]FIG. 3 illustrates the opposite side of the substrate illustrated in FIG. 2;

[0018]FIG. 4 illustrates first and second mold sections which define a mold cavity;

[0019]FIG. 5 illustrates the portion of the substrate shown in FIGS. 2 and 3 positioned in the mold cavity;

[0020]FIG. 6 illustrates the sequence of filling the mold cavity;

[0021]FIGS. 7 and 8 are perspective and plan views, respectively, of a first side of the portion of the substrate illustrated in FIGS. 2 and 3, after encapsulation;

[0022]FIGS. 9 and 10 are perspective and plan views, respectively, of a second side of the portion of the substrate illustrated in FIGS. 2 and 3, after encapsulation;

[0023]FIGS. 11 and 12 are views taken along the lines XI and XII, respectively, in FIG. 10;

[0024]FIGS. 13A and 13B illustrate an asymmetric encapsulated device; and

[0025]FIG. 14 illustrates another gate arrangement which may be used with the method of the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0026]FIG. 1 illustrates a substrate 10 which may be used in conjunction with the method of the present invention. The description of the method of the present invention in connection with the substrate 10 is for purposes of illustration only, and not limitation. It is anticipated that the method and molds of the present invention may be used to encapsulate a large variety of articles, both electrical and non-electrical. In FIG. 1, the substrate is a known flexible substrate suitable for receiving electrical devices 12 in openings 14. The electrical device may be any type of device, although a memory device is shown in FIG. 1.

[0027] The electrical device 12 may be connected to a first side 16 of the substrate 10 by any known means, e.g. lamination, adhesion, etc. The device 12 may be of a type in which electrical connections extend from the center of the device. The device 12 is positioned such that the electrical connections 18 of the device 12 extend through opening 14 to a second side 20 of substrate 10, seen in FIG. 3. In the remaining pre-singulation figures, only portion 22 of substrate 10 is illustrated for purposes of convenience. The reader will recognize that the description of the method and molds hereinafter with respect to portion 22 is actually carried out “×” times, e.g., 8, 10, 12, etc. depending upon the size and capacity of the encapsulating equipment.

[0028] In FIG. 2 it is seen that the device 12 is positioned such that opening 14 is not completely blocked leaving a small opening referred to as a secondary gate 24. If the device 12 completely blocks opening 14, then an alternate means of providing encapsulating material must be provided as described below.

[0029] In FIG. 3, the second side 20 of the portion 22 of the substrate 10 is illustrated. Second side 20 has traces 26 formed therein. The traces 26 may be formed using a solder masking step as is known in the art. Solder balls 28 may be embedded in portion 22 to provide a termination/connection point for each of the traces 26. After the device 12 is connected to the portion 22 and the electrical connections 18 are extending through opening 14, each electrical connection 18 is connected to one of the traces using any known connection technique and machinery.

[0030] A mold 30 which may be used in conjunction with the method of the present invention is illustrated in FIG. 4. In FIG. 4, a first mold section 32 and a second mold section 34 cooperate to define a mold cavity 36.

[0031]FIG. 5 illustrates the portion 22 positioned within cavity 36. The portion 22 is positioned such that device 12 is entirely within the portion of the cavity 36 formed by the first mold section 32, although, for other devices that may not be the case. Similarly, opening 14, and the connection of the electrical connections 18 to traces 26 is positioned entirely within the portion of the cavity 36 formed by the second mold section 34.

[0032] The asymmetry of the mold sections 32, 34 can be clearly seen in FIGS. 4 and 5. In this illustrated embodiment, the surface area of the mold section 32 is approximately three times greater than a surface area of the mold section 34. Generally, the surface area (A16) of the first side 16 of portion 22 facing mold cavity 36 must be greater than the surface area (A20) of the second side 20 of portion 22 facing mold cavity 36. That is A16>A20.

[0033] Another by-product of the asymmetry is that first mold portion 32 may be sealed against the first surface 16 of portion 22 by applying clamping pressure in the four areas marked 38. No such seal can be formed at this time between second mold portion 34 and the second surface 20 of portion 22 because no clamping pressure can be exerted in opposition to the two areas marked 40. Not shown in FIGS. 4 and 5 is a runner and primary gate, which is the mechanism for injecting the encapsulating material into the portion of the mold cavity formed by the first mold section 32.

[0034] Turning now to FIG. 6, the sequential flow of encapsulating material into the mold cavity 34 is shown. Encapsulating material flows under pressure through runner 42 into the portion of the mold cavity formed by first mold section 32. The pressure in runner 42 is designated PI while the pressure in the portion of the mold cavity formed by first mold section 32 is designated P2. The encapsulating material passes through secondary gate 24 at a pressure of P3 and into the portion of the mold cavity formed by second mold section 34 at a pressure of P4. The pressure is controlled such that P1>P2>P3>P4.

[0035] In one embodiment, the encapsulation material is a thermo-set epoxy resin mixture and may be loaded under a pressure in the range of 500-2000 psi. Fill times when the encapsulation material is a thermo-set epoxy resin mixture are on the order of 3-10 seconds. The injection pressure and fill times are dependent upon the specific encapsulating material that is used.

[0036] As the encapsulation material fills the portion of the mold cavity formed by the first mold section 32, the portion 22 of the substrate 10 bends or flexes under the pressure exerted by the encapsulation material. The bending brings the second surface 20 into a sealing engagement with the second molding section 34. Thus, a seal is dynamically formed as a portion of the mold cavity formed by the first mold section 32 is filled. In low-pressure applications, it is anticipated that a force may be exerted to cause the bending to take place.

[0037] The encapsulation material may be chosen from a class consisting of epoxies (including thermo-set resins), silicones, sycar, polyimides, and polyurethanes. These encapsulation materials are suitable for use when encapsulating electronic components because they have low moisture permeability, high mobile ions barriers, good UV-VIS and alpha particle protection, favorable mechanical, electrical and physical properties, as well as a low dielectric constant to reduce the device propagation delay and high thermal conductivity to dissipate heat generated by the devices. The proper choice of encapsulation material can enhance reliability of the device and improve its mechanical and physical properties. An optional curing step may hereinafter be required, depending upon the choice of encapsulation material, followed by removal of the mold sections 32, 34.

[0038] After the mold sections 32, 34 are removed, the encapsulated electronic device appears as shown in FIGS. 7, 8, 9, and 10. FIGS. 7 and 8 show the first side 16 of portion 22 after removal of mold section 32. A first portion of encapsulated material 33 is formed as a result of the encapsulation material being loaded into mold section 32. FIGS. 9 and 10 show the second side 20 of portion 22 after removal of mold section 34. A second portion of encapsulated material 35 is formed as a result of the encapsulation material being loaded into mold section 34.

[0039]FIGS. 11 and 12 illustrate views taken along the lines XI and XII, respectively, in FIG. 10. FIG. 12 provides a view of runner 42 and primary gate 44, which is the mechanism for injecting the encapsulation material into the portion of the mold cavity formed by the first mold section 32.

[0040]FIGS. 13A and 13B show the final product of the present invention after singulation, i.e. after portions of the substrate 22 are separated and the runner 42 is removed.

[0041]FIG. 14 shows another gate arrangement which may be used with the method of the present invention. The electrical device to be encapsulated is a memory device identical to the one as shown in previous FIGS. 1 through 13B, although the electrical device may be any type of device. The electrical device 12 is positioned such that opening 14 (see FIG. 1) is completely blocked. Thus encapsulating material injected into first mold section 32 from runner 42 and primary gate 44 is contained within first mold section 32. That is, there is no connecting gate between first mold section 32 and second mold section 34 through which encapsulation material may flow. Encapsulating material may be injected directly into mold section 34 through a gate 46 and a runner, not shown. The encapsulating material injected into mold section 34 is contained within mold section 34.

[0042] While the present invention has been described in conjunction with preferred embodiments thereof, those of ordinary skill will recognize that many modifications and variations thereof are possible. For example, a limitless number of asymmetric mold designs are possible. It is anticipated that the method of the present invention may be carried out using a variety of encapsulating materials and commercially available injection molding machines. Also, numerous other gate configurations are possible. The foregoing description and the following claims are intended to cover all such modifications and variations. 

What is claimed is:
 1. A method of encapsulating an article having first and second surfaces, comprising: positioning a first molding section in a sealing relationship with the first surface of the article; positioning a second molding section adjacent the second surface of the article; filling the first molding section thereby forcing the second surface of the article into a sealing engagement with the second molding section; and filling the second molding section.
 2. The method of claim 1 wherein said step of filling said first and second molding sections includes the step of filling said first and second molding sections with an encapsulating material chosen from a class consisting of epoxies, including thermo-set resins, silicones, sycar, polyimides, and polyurethanes.
 3. The method of claim 2 including the step of curing said encapsulating material.
 4. A method of encapsulating an electrical device positioned on a flexible substrate, comprising: positioning a portion of the flexible substrate carrying the electrical device within a molding cavity defined by first and second molding sections, said substrate forming a seal with the first molding section; forming a seal between the substrate and the second molding section by filling the first molding section; and filling the second molding section.
 5. The method of claim 4 wherein said step of filling said first and second molding sections includes the step of filling said first and second molding sections with a thermo-set resin.
 6. The method of claim 4 including the step of curing said thermo-set resin.
 7. A method, comprising: mounting an electrical device on a first surface of a flexible substrate such that leads from the electrical device extend to a second surface of the flexible substrate; connecting the leads to traces formed in the second surface of the flexible substrate; positioning a portion of the flexible substrate carrying the electrical device within a molding cavity defined by first and second molding sections, said substrate forming a seal with the first molding section; forming a seal between the substrate and the second molding section by filling the first molding section; and filling the second molding section.
 8. The method of claim 7 wherein said step of positioning a portion of the flexible substrate carrying the electrical device within a molding cavity results in the electrical device being located completely within the first molding section.
 9. The method of claim 8 wherein said step of positioning a portion of the flexible substrate carrying the electrical device within a molding cavity results in the leads and connections to traces being located completely within the second molding section.
 10. The method of claim 7 wherein said step of filling said first and second molding sections includes the step of filling said first and second molding sections with a thermo-set resin to form a molded article.
 11. The method of claim 10 including the step of curing said thermo-set resin.
 12. The method of claim 7 including the step of removing said molded article from the molding cavity.
 13. The method of claim 7 including the step of separating said portion of the flexible substrate carrying the electrical device from the remaining portion of the substrate.
 14. The method of claim 7 wherein said step of positioning said portion of the flexible substrate carrying the electrical device within said molding cavity results in the creation of a path between the portion of the cavity defined by said first molding section and the portion of the cavity defined by said second molding section.
 15. A method of dynamic encapsulation, comprising: filling a first molding cavity positioned in a sealing relationship with an article to be encapsulated; dynamically creating a sealing relationship between the article and a second molding cavity; and filling the second molding cavity.
 16. The method of claim 15 wherein said step of dynamically creating a sealing relationship includes the step of allowing the article to flex into a sealing engagement with the second molding cavity.
 17. A method, comprising: mounting an electrical device to a first surface of a flexible substrate such that leads from the electrical device extend to a second surface of the flexible substrate; connecting the leads to traces formed in the second surface of the flexible substrate; positioning a portion of the flexible substrate carrying the electrical device within a molding cavity defined by first and second molding sections, said substrate forming a seal with the first molding section; filling the first molding cavity to dynamically create a sealing relationship between the flexible substrate and the second molding cavity; and filling the second molding cavity.
 18. The method of claim 17 wherein said step of positioning a portion of the flexible substrate carrying the electrical device within a molding cavity results in the electrical device being located completely within the first molding section.
 19. The method of claim 18 wherein said step of positioning a portion of the flexible substrate carrying the electrical device within a molding cavity results in the leads and connections to traces being located completely within the second molding section.
 20. A method of transfer molding, comprising: positioning a first portion of encapsulated material on a first surface by transfer molding; and positioning a second portion of encapsulated material, of smaller surface area than said first portion, on a second surface by transfer molding.
 21. A mold, comprising: a first molding section; a second molding section, said first and second molding sections forming a cavity for receiving an article to be encapsulated, said cavity designed such that a first surface area of the article exposed to the cavity is greater than a second surface area of the article exposed to the cavity; and at least one gate for injecting encapsulating material into said cavity.
 22. The mold of claim 21 wherein a surface area of the first molding section is greater than a surface area of the second molding section.
 23. The mold of claim 21 comprising a primary gate and a secondary gate, said primary gate and said secondary gate being configured to allow the portion of said cavity having the larger surface area to fill first.
 24. The mold of claim 21 designed to withstand a psi of approximately 500-2000 psi and a filling time of approximately 3-10 seconds.
 25. A transfer mold comprised of a first molding section and a second molding section, said molding sections defining a molding cavity, and wherein there exists a differential in surface area defining said cavity between the first molding section and the second molding section.
 26. A system, comprising: a device to be encapsulated, said device comprising a first surface and a second surface; and a mold, said mold comprising: a first molding section; a second molding section, said first and second molding sections forming a cavity for receiving said device, said cavity designed such that a first surface area of the article exposed to the cavity is greater than a second surface area of the article exposed to the cavity; and at least one gate for injecting encapsulating material into said cavity.
 27. The system of claim 26 wherein a surface area of the first molding section is greater than a surface area of the second molding section.
 28. The system of claim 26 comprising a primary gate and a secondary gate, said primary gate and said secondary gate being configured to allow the portion of said cavity having the larger surface area to fill first.
 29. The system of claim 26 designed to withstand a psi of approximately 500-2000 psi and a filling time of approximately 3-10 seconds.
 30. The system of claim 26 wherein said device is an electrical device.
 31. The system of claim 30 wherein said device is a memory device.
 32. A non-symmetrical, transfer molded, encapsulated article.
 33. An encapsulated article, comprising: an article having first and second surfaces; a first portion of encapsulated material positioned on said first surface by transfer molding; and a second portion of encapsulated material, of smaller surface area than said first portion, positioned on said second surface by transfer molding.
 34. An asymmetric, transfer molded, encapsulated electronic device mounted upon a substrate.
 35. The device of claim 34 wherein a larger area of encapsulation material covers the device.
 36. The device of claim 35 wherein a smaller area of encapsulation material covers electrical connectors and connections to traces on the substrate.
 37. An encapsulated memory device mounted upon a substrate, comprising: a substrate having first and second surfaces; a first portion of encapsulated material positioned on said first surface by transfer molding; and a second portion of encapsulated material, of smaller surface area than said first portion, positioned on said second surface by transfer molding. 